Charging Socket Heatpipe Layout for Closed-Housing Cooling
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Solution Overview
Problem
Existing plug connector parts, particularly charging sockets in electric vehicles, face inadequate heat dissipation due to closed housings, leading to increased resistance and hindered charging efficiency during high-current DC charging processes.
Innovation Solution
A passively cooled heat conductor, such as a heatpipe, is connected to electrical contact elements and extends through a housing opening, with a heat sink positioned externally to facilitate effective heat dissipation via convection, using electrical insulation to prevent voltage or current transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a closed housing is used for the charging socket, then protection against weather elements is improved, but heat dissipation from the contact elements deteriorates
Solution Approach 1:
The heat sink is extracted from the closed housing and positioned externally, allowing it to access ambient air for effective heat dissipation while the housing remains closed and protected against weather elements. The heat conductor serves as the extraction pathway, conducting heat from the contact elements through the housing wall to the external heat sink.
2Productivity
If high current is used for DC charging, then charging speed is improved, but heat generation at contact elements increases
Solution Approach 1:
The heat generated by high current charging, which is initially harmful, is converted into a manageable thermal flow path. The heat conductor and external heat sink system channels this heat away from the contact elements, allowing high current charging to proceed at full speed without thermal damage, thus converting the harmful heat into a controlled thermal management process.
3Device complexity
If a heat sink is placed inside the housing, then heat dissipation path is simplified, but heat build-up occurs due to confined space
Solution Approach 1:
The heat sink is moved from the internal three-dimensional confined space to an external position, utilizing the external ambient space for heat dissipation. This dimensional transition from internal to external placement allows the heat sink to access unlimited ambient air for convection and radiation, eliminating heat build-up while maintaining a simple heat dissipation path through the heat conductor.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly enhances heat dissipation by allowing the heat sink to efficiently dissipate heat to ambient air, reducing thermal build-up and improving charging efficiency by maintaining effective electrical insulation and convection.
Implementation Method 1
a passively cooled heat conductor, such as a heatpipe, is connected to electrical contact elements and extends through a housing opening, with a heat sink positioned externally to facilitate effective heat dissipation
Implementation Method 2
allowing the heat sink to efficiently dissipate heat to ambient air, reducing thermal build-up and improving charging efficiency by maintaining effective electrical insulation and convection
Implementation Method 3
using electrical insulation to prevent voltage or current transfer
Data Source
AI summary
The invention relates to a plug connector part for mechanical and electrical connection to a mating plug connector part, in particular a motor-vehicle-side charging socket (1) for coupling to a charging plug as components of an electrical charging infrastructure for electric or hybrid motor vehicles, or vice versa. To this end, a housing (2, 3) and at least one electrical contact element (4) located in the housing (2, 3) are provided. Moreover, a passively cooled heat conductor (7) is provided, one end (7a) of which is connected to the contact element (4) and the other end (7b) of which has a heat sink (8). According to the invention, the heat conductor (7) extends through a housing opening (2a, 3a) and is equipped outside the housing (2, 3) with the heat sink (8) arranged there.